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At least 541 records · Page 30

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NASA NTRS1983

Flight service evaluation of composite helicopter components

This first interim report presents the technical background for including environmental effects in the design of helicopter composite structures, and test results after approximately two year field exposure of components and panels. Composite structural components were removed from Sikorsky S-76 helicopters commercially operated in the Gulf Coast region of Louisiana. Fatigue tests were conducted for a graphite/epoxy tail rotor spar and static test for a graphite/epoxy and Kevlar/epoxy stabilizer. Graphite/epoxy and Kevlar/epoxy panels are being exposed to the outdoor environment in Stratford, Connecticut and West Palm Beach, Florida. For this reporting period the two year panels were returned, moisture measurements taken, and strength tests conducted. Results are compared with initial type certificate strengths for components and with initial laboratory coupon tests for the exposed panels. Comparisons are also presented with predicted and measured moisture contents.

Rich, M. J.↗

NASA NTRS1985

Effects of a high mean stress on the high cycle fatigue life of PWA 1480 and correlation of data by linear elastic fracture mechanics

High-cycle fatigue tests using 5-mm-diameter smooth specimens were performed on the single crystal alloy PWA 1480 (001 axis) at 70F (room temperature) in air and at 100F (538C) in vacuum (10 to the -6 power torr). Tests were conducted at zero mean stress as well as at high tensile mean stress. The results indicate that, although a tensile mean stress, in general, reduces life, the reduction in fatigue strength, for a given mean stress at a life of one million cycles, is much less than what is predicted by the usual linear Goodman plot. Further, the material appears to be significantly more resistant to mean stress effects at 1000F than at 70F. Metallographic examinations of failed specimens indicate that failures in all cases are initiated from micropores of sizes of the order of 30 to 40 microns. Since the macroscopic stress-strain response in all cases was observed to be linear elastic, linear elastic fracture mechanics (LEFM) analyses were carried out to determine the crack growth curves of the material assuming that crack initiation from a micropore (a sub o = 40 microns) occurs very early in life. The results indicate that the calculated crack growth rates at an R (defined as the ratio between minimum stress to maximum stress) value of zero are approximately the same at 70F as at 1000F. However, the calculated crack growth rates at other R ratios, both positive and negative, tend to be higher at 70F than at 1000F. Calculated threshold effects at large R values tend to be independent of temperature in the temperature regime studied. They are relatively constant with increasing R ratio up to a value of about 0.6, beyond which the calculated threshold stress intensity factor range decreases rapidly with increasing R ratios.

Majumdar, S.↗

NASA NTRS1993

Evaluation of a vibration diagnostic system for the detection of spur gear pitting failures

A vibration diagnostic system was used to detect spur gear surface pitting fatigue in a closed-loop spur gear fatigue test rig. The diagnostic system, comprising a personal computer with an analog-to-digital conversion board, a diagnostic system unit, and software, uses time-synchronous averaging of the vibration signal to produce a vibration image of each tooth on any gear in a transmission. Several parameters were analyzed including gear pair stress wave and raw baseband vibration, kurtosis, peak ratios, and others. The system provides limits for the various parameters and gives a warning when the limits are exceeded. Several spur gear tests were conducted with this system and vibration data analyzed at 5-min. intervals. The results presented herein show that the system is fairly effective at detecting spur gear tooth surface fatigue pitting failures.

Townsend, Dennis P.↗

NASA NTRS1993

Evaluation of a vibration diagnostic system for the detection of spur gear pitting failures

Townsend, Dennis P.↗

DOE OSTI2025

FY25 Planned High-Temperature Mechanical Tests of LPBF 316H SS Performance at INL

This document is not the full report but contains the contribution to the Argonne National Laboratory’s Milestone which presents the consolidated research report on the laser powder bed fusion 316H material. This document provides an update on the creep and creep-fatigue test effort at Idaho National Laboratory.

316H Steel↗

NASA NTRS2014

Property Evaluation and Damage Evolution of Environmental Barrier Coatings and Environmental Barrier Coated SiC/SiC Ceramic Matrix Composite Sub-Elements

This paper describes recent development of environmental barrier coatings on SiC/SiC ceramic matrix composites. The creep and fatigue behavior at aggressive long-term high temperature conditions have been evaluated and highlighted. Thermal conductivity and high thermal gradient cyclic durability of environmental barrier coatings have been evaluated. The damage accumulation and complex stress-strain behavior environmental barrier coatings on SiCSiC ceramic matrix composite turbine airfoil subelements during the thermal cyclic and fatigue testing of have been also reported.

Creep and fatigue↗

NASA NTRS1981

Corrosion fatigue of Inconel 718 and Incoloy 903

Corrosion fatigue tests were conducted on Inconel 718 and Incoloy 903 in distilled water, 500 ppm NaCl, and 3.5% NaCl. Results were compared to the endurance limit in air. For Inconel 718, the corrosion fatigue strength (CFS) IN 3.5% NaCl WAS 328 MPa or 75 percent of the endurance limit. For Incoloy 903, the CFS ranged from 234 MPa in distilled water (68 percent of the endurance limit) to 103 MPa in 3.5% NaCl (30 percent of the endurance limit). Results indicate that, for components which have limited fatigue life, an evaluation of the combined effects of fatigue and the corrosive atmosphere must be considered in projecting useful lifetimes.

Franklin, D. B.↗

NASA NTRS2003

Erosion Resistant Coatings for Polymer Matrix Composites in Propulsion Applications

Polymer Matrix Composites (PMCs) offer lightweight and frequently low cost alternatives to other materials in many applications. High temperature PMCs are currently used in limited propulsion applications replacing metals. Yet in most cases, PMC propulsion applications are not in the direct engine flow path since particulate erosion degrades PMC component performance and therefore restricts their use in gas turbine engines. This paper compares two erosion resistant coatings (SANRES and SANPRES) on PMCs that are useful for both low and high temperature propulsion applications. Collaborating over a multi-year period, researchers at NASA Glenn Research Center, Allison Advanced Developed Company, and Rolls-Royce Corporation have optimized these coatings in terms of adhesion, surface roughness, and erosion resistance. Results are described for vigorous hot gas/particulate erosion rig and engine testing of uncoated and coated PMC fan bypass vanes from the AE 3007 regional jet gas turbine engine. Moreover, the structural durability of these coatings is described in long-term high cycle fatigue tests. Overall, both coatings performed well in all tests and will be considered for applications in both commercial and defense propulsion applications.

Sutter, James K.↗

NASA NTRS2018

Advanced Environmental Barrier Coating and SA Tyrannohex SiC Composites Integration for Improved Thermomechanical and Environmental Durability

The development of 2700 degF capable environmental barrier coating (EBC) systems, particularly, the Rare Earth "Hafnium" Silicon bond coat systems, have significantly improved the temperature capability and environmental stability of SiC/SiC Ceramic Matrix Composite Systems. We have specifically developed the advanced 2700 degF EBC systems, integrating the EBC to the high temperature SA Tyrannohex SiC fiber composites, for comprehensive performance and durability evaluations for potential turbine engine airfoil component applications. The fundamental mechanical properties, environmental stability and thermal gradient cyclic durability performance of the EBC - SA Tyrannohex composites were investigated. The paper will particularly emphasize the high pressure combustion rig recession, cyclic thermal stress resistance and thermomechanical low cycle fatigue testing of uncoated and environmental barrier coated Tyrannohex SiC SA composites in these simulated turbine engine combustion water vapor, thermal gradients, and mechanical loading conditions. We have also investigated high heat flux and flexural fatigue degradation mechanisms, determined the upper limits of operating temperature conditions for the coated SA composite material systems in thermomechanical fatigue conditions. Recent progress has also been made by using the self-healing rare earth-silicon based EBCs, thus enhancing the SA composite hexagonal fiber columns bonding for improved thermomechanical and environmental durability in turbine engine operation environments. More advanced EBC- composite systems based on the new EBC-Fiber Interphases will also be discussed.

Tyrannohex SiC Ceramics↗

DOE OSTI2022

Mechanical joint performances of friction self-piercing riveted carbon fiber reinforced polymer and AZ31B Mg alloy

Carbon fiber reinforced polymer (CFRP) and AZ31B Mg alloy were joined by the friction self-piercing riveting (F-SPR) with different steel rivet shank sizes. With the increase of rivet shank size, lap shear fracture load and mechanical interlock distance increased. Ultrafine grains were formed at the joint in AZ31B as a result of dynamic recrystallization, which contributed to the higher hardness. Fatigue life of the CFRP-AZ31B joint was studied at various peak loads of 0.5, 1, 2, and 3 kN and compared with the resistance spot welded AZ31B-AZ31B from the open literature. The fatigue performance was better at higher peak load (>2 kN) and comparable to that of resistance spot welding of AZ31B to AZ31B at lower peak loads (<1 kN). From fractography, the crack initiation for lower peak load (<1 kN) case was observed at the fretting positions on the top and bottom surfaces of AZ31B sheet. When peak load was increased, fretting between the rivet and the top of AZ31B became more dominant to initiate a crack during fatigue testing.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Fatigue behavior of low-cost, non-spherical Ti-6Al-4V powder processed via laser powder bed fusion

Hydride-dehydride Ti-6Al-4V powder with particle size distribution of 75–175 μm were used to manufacture fatigue samples. Optimized processing parameters were used to maintain a relative density of >99.5% in the samples. Fatigue tests were carried out in R = σ min /σ max = -1 condition under stresses ranging from 150 to 500 MPa and the results were compared to samples that were additively manufactured using spherical powders. The fatigue lives were similar between the two types of powder; i.e., powder morphology has no effect on fatigue performance. However, the high surface roughness and martensitic microstructure resulting from the laser powder bed fusion process result in poor performance compared to samples machined from conventionally produced materials. In conclusion, crack initiation occurred consistently from surface defects because of high surface roughness of the additively manufactured parts.

36 MATERIALS SCIENCE↗

NASA NTRS1956

Interim Report on Fatigue Characteristics of a Typical Metal Wing

Constant amplitude fatigue tests of seventy-two P-51D "Mustang" wings are reported. The tests were performed by a vibrational loading system and by an hydraulic loading device for conditions with and without varying amounts of pre-load. The results indicate that: (a) the frequency of occurrence of fatigue at any one location is related to the range of the loads applied, (b) the rate of propagation of visible cracks is more or less constant for a large portion of the life of the specimen, (c) the fatigue strength of the structure is similar to that of notched material having a theoretical stress concentration factor of more than 3.0, (d) the frequency distribution of fatigue life is approximately logarithmic normal, (e) the relative increase in fatigue life for a given pre-load depends on the maximum load of the loading cycle only, while the optimum pre-load value is approximately 85 percent of the ultimate failing load, and (f) that normal design procedure will not permit the determination of local stress levels with sufficient accuracy to determine the fatigue strength of an element of a redundant structure.

LOADS AND STRESSES, STRUCTURAL - REPEATED DYNAMIC↗

NASA NTRS1981

Ion beam deposited protective films

Sputter deposition of adherent thin films on complex geometric surfaces by ion beam sources is examined in order to evaluate three different types of protective coatings for die materials. In the first experiment, a 30 cm diameter argon ion source was used to sputter deposit adherent metallic films up to eight microns thick on H-13 steel, and a thermal fatigue test specimen sputter deposited with metallic coatings one micron thick was immersed in liquid aluminum and cooled by water for 15,000 cycles to simulate operational environments. Results show that these materials do protect the steel by reducing thermal fatigue and thereby increasing die lifetime. The second experiment generated diamond-like carbon films using a dual beam ion source system that directed an eight cm argon ion source beam at the substrates. These films are still in the process of being evaluated for crystallinity, hardness and infrared absorption. The third experiment coated a fiber glass beam shield incorporated in the eight-cm diameter mercury ion thruster with molybdenum to ensure proper electrical and thermal properties. The coating maintained its integrity even under acceleration tests.

Mirtich, M. J.↗

NASA NTRS1972

Mechanical component screening for scanner

The critical mechanical components of the scan mirror mechanism are described and their evaluation and screening procedures are discussed. A bumper/damper unit is used in the design to reverse motion of the mirror and effect scan and retrace cycles. A wear evaluation was conducted on the bumper impact surfaces that established nylon 6-10 as an acceptable material. The elastomeric dampers were subjected to thermal vacuum tests for condensables and outgassing as well as parametric life tests. The flexure pivots that support the mirror were tested to establish a curve of stress plotted as a function of cycles to failure for rotational operation. The pivots met the life requirement of 150,000,000 cycles at a + or - 2.9 deg amplitude during fatigue testing. Screening procedures were established for dampers and flexure pivots to obtain flight quality components.

Olson, J. L.↗

NASA NTRS1982

Effect of shot peening on surface fatigue life of carburized and hardened AISI 9310 spur gears

Surface fatigue tests were conducted on two groups of AISI 9310 spur gears. Both groups were manufactured with standard ground tooth surfaces, with the second group subjected to an additional shot peening process on the gear tooth flanks. The gear pitch diameter was 8.89 cm (3.5 in.). Test conditions were a gear temperature of 350 K (170 F), a maximum Hertz stress of 1.71 billion N/sq m (248,000 psi), and a speed of 10,000 rpm. The shot peened gears exhibited pitting fatigue lives 1.6 times the life of standard gears without shot peening. Residual stress measurements and analysis indicate that the longer fatigue life is the result of the higher compressive stress produced by the shot peening. The life for the shot peened gear was calculated to be 1.5 times that for the plain gear by using the measured residual stress difference for the standard and shot peened gears. The measured residual stress for the shot peened gears was much higher than that for the standard gears.

Townsend, D. P.↗

DOE OSTI2022

Stress-controlled fatigue of HfNbTaTiZr high-entropy alloy and associated deformation and fracture mechanisms

The stress-controlled fatigue tests are carried out at a stress ratio of 0.1 and a frequency of 10 Hz, and span both low-cycle and high-cycle regimes by varying the applied stress amplitudes. The high-cycle fatigue regime gives a fatigue strength of 497 MPa and a fatigue ratio of 0.44. At equivalent conditions, the alloy's fatigue strength is greater than all other high-entropy alloys (HEAs) with reported high-cycle fatigue data, dilute body-centered cubic alloys, and many structural alloys such as steels, titanium alloys, and aluminum alloys. Through in-depth analyses of crack-propagation trajectories, fracture-surface morphologies and deformation plasticity by means of various microstructural analysis techniques and theoretical frameworks, the alloy's remarkable fatigue resistance is attributed to delayed crack initiation in the high-cycle regime, which is achieved by retarding the formation of localized persistent slip bands, and its good resistance to crack propagation in the low-cycle regime, which is accomplished by intrinsic toughening backed up by extrinsic toughening. Additionally, the stochastic nature of the fatigue data is neatly captured with a 2-parameter Weibull model.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Service life of metals at low temperatures

Current concepts of the nature of fatigue failure at low temperatures are presented on the basis of experimental results of various investigators. The fundamental approach to the technique for studying low-temperature fatigue is examined. The necessity for using the same medium at different fatigue test temperatures and also the necessity for taking into account the magnitude of the plastic deformation amplitude are confirmed. Experimental data from a study of the influence of low temperatures (down to liquid nitrogen temperatures) on the fatigue life of copper and armco-iron in dry air, over a wide range of deformations, are presented. These results are compared with microscopic and electron microscopic pictures of the surface of the deformed specimens.

Verkin, B. I.↗

NASA NTRS1979

Development of high-cycle fatigue design curves for a cast aluminum alloy

Life prediction curves for rocket engine pump parts were developed from the results of high-cycle fatigue tests run on cast-aluminum specimens. Notched and smooth specimens were cyclically tested at different mean stress levels at -320 F (78 K). The notch size and mean stress enveloped the design operating conditions. Local stress computed in the groove of the notched specimen was used to represent its fatigue strength. The von Mises criterion was used to determine effective cyclic stresses. The Goodman rule was applied to determine equivalent reversed alternating stresses. The procedure permitted the notched and smooth data sets to each be described by a single curve. High-cycle fatigue life curves were provided for the stress state, mean stress, and stress concentration spanned by the data.

Cooper, R. A.↗